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Wednesday, 18 May 2011

Unexpected mechanical faliure

After my filament tangle and snapping incident printing the Octopus I started printing the great looking minimalistic spool (thing 8472) by whosawhatsis when half way through the print some odd noises started to happen and then my X axis Flexi-drive snapped.

After removal.

I was just about half way through the print when it happened, I shut the machine down and investigated.

Just after it snapped.

Old photo of before the failure - clearly bad motor-shaft alignment.

I found a photo of what is looked like before it snapped and the only thing I could see were two of the flexi-compression rings seemed to be very close together and the whole flexi-drive looked compressed.

So I expect that it was under some strain and eventually failed.

I still don't really know why it snapped. I'm not using acceleration so maybe along with the NEMA23 motors running with 24V I'm pushing my machine too fast and hard?

New installed flexi-drive and silicon pad + washers to help get better horizontal alignment.

I had a spare flexi-drive so I fitted that and used washers to space the motor out to give better alignment and a small silicone pad under the motor mount to allow some freedom for any oscillation, I hope this will not make the problem worse, time will tell if this happens again or maybe I was just unlucky with a weak part? or it was just the bad motor shaft alignment.

Not wanting to waste a good hour of printing I wanted to restart it, so after a height measurement of the part I concluded it must have failed around Layer 62, so a quick edit of the GCODE to start at layer 61, I re-started the print, the first layer bonded well with the last and it was off again.

First useful part printed. and one of the largest things I have printed so far.

The print finished later with no other issues and part is usable if not a little out of alignment where I nudged the opto-switch when taking the motor off.

I also checked the Y axis motor mount and that looks fine, so I hope this was just a one off event.

I will print the Filament mount arms tonight and hopefully assemble it, that will be the first useful thing it's printed and it should allow me to leave the machine for longer without worrying about filament tangle.

Thanks to whosawhatsis for the great model, I'm sure this is going to look great on my machine.

203 comments:

WRT the layer alignment, my X axis skipped during an attempt to print this part, and though I managed to get it to where it appeared to be properly aligned after a couple of layers, I couldn't get the bearings to align properly. This prevented them from turning smoothly and made the whole assembly wobble, so I had to scrap the print.

You should be able to print it faster by reducing the infill, though. Give it two shells and three or four layers for solid surfaces, and you don't need much infill at all. Making it too heavy won't help the functionality, and mine is plenty strong enough printed as I described.

I have not experimented with more shells yet, but I need to take the skeinforge plunge soon so I'll have loads more options to play with.

I just got the 3 arms printed with less infill, they work really great. the bearings fitted perfectly and alignment on the studding is very good. The filament holder is now in use and I'm just printing another Octopus. I'll post a photo of it fitted onto my machine tomorrow.

Looking at your photos it does not seem to be 'in alignment'. These devices are frequently Aluminium and it looks like classic Aluminium fatigue.

Check the maximum permissible miss-alignment for the coupling and measure your miss-alignment with a dial indicator or equivalent home brew device. It's tricky to tell for sure but it looks to me like you have exceeded it. Couplings have to be aligned in three axis and the total miss-alignment accounted for. It may seem strange but the job of this coupling is to allow for 'minor' miss alignment and to prevent axial thrust transfer into the bearings of say a rather expensive shaft encoder.

http://en.wikipedia.org/wiki/Fatigue_limit

Simple rule, coupling life is directly related to degree of alignment.

Think of it this way. Aluminium work hardens and you are flexing it every time it rotates!

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Satta bazaar in repair, as IPL goes into cold storage with different primary carrying routineMumbai: Put your final fiver on this: the satta bazaar is in a repair. throughout the globe, the percentages are that bookies and punters have their finger on the panic button, with everyone making an attempt to pip the others to the publish to discover a way out of this coronavirus pandemic. The suspension of the Indian Premier League (IPL) except further be aware has simplest rubbed salt into their wound."yes, this is a big jolt and will additional dig into the pockets of bookies who have already taken funds for the semi-finalists, finalists and the top of the line winner of the 2020 season," mentioned a bookie on circumstances of anonymity.The Mumbai Indians and Sunrisers Hyderabad have been on the excellent of their charts as the favourites, at Nos. 1 and a couple of respectively. Sunrisers and Mumbai Indians were on 5.5 while Chennai and Delhi Capitals on 5.7 and 7.four in the third and the fourth on the betting radar respectively.Now, the bookies will ought to pay back the funds to punters, as the experience is virtually called off this season. it is being given to remember that a sum of Rs 2,000 crore had exchanged arms even earlier than the event might get underway.The probability of the emergence of the sort of scenario must have on no account crossed their minds. whereas there looks to be a way out for bookmakers and punters to an extent, when it comes to world guessing games, there are bets accredited for all manner of races below the sun, from pigeon to dog racing."sure, we must preserve, which is the purpose the having a bet world grabs each chance that comes its approach," pointed out a bookie, including that even the Indian matka market has joined the crowd. all of the entire operations are conducted in Dubai."Dubai has been our hub and there is some motion," talked about the bookie concerning the operations. despite the fact, the motion is limited to definite sections handiest, as many in this trade are actually residing off their reductions, whereas others are making inroads into this project.in the meantime, the activities making a bet neighborhood in London is getting set for a digital summit from April 27 to might also 1. around a hundred and forty audio system, including more than 20 CEOs of foremost bookmakers from throughout Europe, the united states and Latin the usa, are anticipated to have their fingers in this emergency pie, so to communicate."it's doubtless fair to explain this as an 'emergency summit', as the significant theme across all 5 days may be how to continue to exist the hunch and soar lower back as soon as regular company operations resume," SBC president Andrew McCarron pointed out, speaking to a bit of the media. "CEOs of many leading operators everywhere could be taking part, so we'll see loads of respectable ideas shared.Given the enjoyable instances, I feel there'll even be discussions about how agencies can work collectively for the lengthy-time period good of the wider industry and its purchasers," he noted. UK punters stake around £250 million ($312 million) on the Grand national on my own, and that type of income is impossible to exchange.besides the fact that children, he says that punters generally are creatures of addiction so even as the on-line bookmakers can be credited with being inventive, the rewards go nowhere close replacing the losses in profits. after all, having a bet is a sort of amusement enjoyed by tens of millions of individuals.Satta MatkaSattaMatka

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